START-UP INSTRUCTION START-UP CHECKLIST SERIES 5 36000 To 72000 BTU S PACKAGE UNITS 3 To 6 Ton Date: _ Job Name: Customer Name: Address: City: State: Zip: Model Number: Serial Number: Qualified Start-up Technician: HVAC Contractor: Phone: Address: Contractor s E-mail Address: HVAC Start-up Technician s Signature: Electrical Contractor: Phone: ADDITIONAL WARRANTY STATEMENT Johnson Controls/UPG is confident that this equipment will operate to the owner's satisfaction if the proper procedures and checks are made at initial start-up. This confidence is supported by the DOA portion of our standard warranty policy which states that Johnson Controls/UPG will cover parts and labor on all parts if they fail within 30 days of start-up. In addition, Johnson Controls/ UPG will cover labor on compressors if they fail within 30 days of start-up. This DOA parts and labor policy is only valid if startup is performed per this checklist by a technician qualified by Johnson Controls/UPG on Series 5 packaged equipment. This warranty statement is in addition to all other warranties provided with the equipment and subject to all of the of the stated limitations. This equipment must be started by a Series 5 Qualified Technician. In the event that communication with Johnson Controls/UPG is required regarding technical and/or warranty concerns, all parties to the discussion should have a copy of the equipment start-up sheet for reference. The start-up sheet must have been completed, dated and signed by a Series 5 Qualified Technician to be valid. A copy of the original start-up sheet must be on file with the Technical Services Department. The Series 5 ton packaged unit is available in constant air volume with a large variety of custom variations and accessories available. Therefore, some variation in the startup procedure will exist depending upon the capacity, control system type, special features and accessories installed. This start-up sheet covers all startup checks and points common to all Series 5 equipment. In addition it covers essential startup checks and points for a number of common installation variations. Depending upon the particular Series 5 unit you are starting not all sections of this startup sheet will apply. Complete those sections applicable and use the notes section to record any additional information pertinent to your particular Series 5 installation. Warranty claims are to be made through the distributor from whom the equipment was purchased. QUALIFIED EQUIPMENT STARTUP The DOA warranty policy requires that the equipment must be inspected and started by a Series 5 Factory Qualified Technician. A copy of the completed start-up sheet should be kept on file by the distributor providing the equipment and a copy sent to: Johnson Controls/UPG Technical Services Department 5005 York Drive Norman, OK 73069 688724-JCL-A-0311
SAFETY WARNINGS The inspections and recording of data outlined in this procedure are required for start-up of Johnson Controls/UPG's Series 5 packaged products. This is not a step-by-step instruction on how to perform these tasks. Industry recognized safety standards and practices must be observed at all times. General industry knowledge and experience are required to assure technician safety. It is the responsibility of the technician to assess all potential dangers and take all steps warranted to perform the work in a safe manner. By addressing those potential dangers, prior to beginning any work, the technician can perform the work in a safe manner with minimal risk of injury. Lethal voltages are present during some start-up checks. Extreme caution must be used at all times. Moving parts may be exposed during some startup checks. Extreme caution must be used at all times. DESIGN APPLICATION INFORMATION NOTE: Read and review this entire document before beginning any of the startup procedures. This information will be available from the specifying engineer who selected the equipment. If the system is a VAV system the CFM will be the airflow when the remote VAV boxes are in the full open position and the frequency drive is operating at 60 HZ. Do not proceed with the equipment start-up without the design CFM information. Design Supply Air CFM: Design Return Air CFM: Design Outdoor Air CFM At Minimum Position: Design Building Static Pressure: Outside Air Temperature Lockout For Cooling: Outside Air Temperature Lockout For Heating: Supply Gas Pressure W/o Heat Active (Static Gas Pressure) Inches ADDITIONAL APPLICATION NOTES FROM SPECIFYING ENGINEER: 2 Unitary Products Group
REFERENCE Item Tech Initials General Inspection Completed Unit inspected for shipping, storage, or rigging damage Unit installed with proper clearances Unit installed within slope limitations Refrigeration system checked for gross leaks (presence of oil) Terminal screws and wiring connections checked for tightness Filters installed correctly and clean Economizer hoods installed in operating position Condensate drain trapped properly Economizer damper linkage tight Gas Heat vent hood installed All field wiring (power and control) complete Item Tech Initials Air Moving Inspection Supply Fan Exhaust Alignment of drive components Belt tension adjusted properly Blower pulleys tight on shaft, blower bearing set screws tight, blower wheel tight to shaft Pressure switch or transducer tubing installed properly Exhaust damper linkage tight Item Tech Initials Operating Measurements - Cooling Fan operates with proper rotation ID Fans Exh. Fans Cond. Fans Pressure drop across dry evaporator coil (At maximum design CFM) 1 Supply Air CFM Supply Air Drive Adjustment 2 Minimum Supply Air Drive Adjustment 2 Maximum 1. Consult the proper airflow to pressure drop table to obtain the actual airflow at the measured pressure differential. 2. Was a motor pulley adjustment or change required to obtain the correct airflow? Was it necessary to increase of decrease the airflow to meet the design conditions? If the motor pulley size was changed, measure the outside diameters of the motor and blower pulleys and record those diameters here; Motor Pulley Pitch Diameter Blower Pulley Pitch Diameter Unitary Products Group 3
ELECTRICAL DATA Supply Voltage Volts Control Voltage Volts L1 - L2 Volts L1 - L3 Volts L2 - L3 Volts Device Nameplate Measured List All Three Amperages Supply Fan Motor AMPS AMPS Exhaust Motor (Dampers 100%) AMPS AMPS Condenser Fan #1 AMPS AMPS Compressor #1 AMPS AMPS REFRIGERANT CIRCUITS Stage Dis. Press Liquid Temp 1 Subcool Suction Press Suction Temp. Superheat First # # 1. Liquid temperature should be taken before filter/drier. Outside air temperature db F Fuel Type: Natural Gas LP Gas OPERATING MEASUREMENT - GAS HEATING Item Tech Initials Action Completed Check for gas leaks Manifold pressure Supply gas pressure at full fire Check temperature rise Stage 1 Stage 2 (If Equipped) Stage 3 (If Equipped) measured or calculated at full fire F OPERATIONAL MEASUREMENTS - STAGING CONTROLS Verify Proper Operation of Heating/Cooling Staging Controls Create a cooling demand at the Thermostat Verify that cooling/economizer stages are energized. Create a heating demand Verify that heating stages are energized. 4 Unitary Products Group
FINAL - INSPECTION Verify that all operational control set points have been set to desired value Scroll through all setpoints and change as may be necessary to suit the occupant requirements. Verify that all option parameters are correct Scroll through all option parameters and ensure that all installed options are enabled in the software and all others are disabled in the software. (Factory software settings should match the installed options) Verify that all access panels have been closed and secured OBSERVED PRODUCT DIFFICIENCIES & CONCERNS: Subject to change without notice. Printed in U.S.A. Copyright 2011 by Unitary Products Group. All rights reserved. 688724-JCL-A-0311 Supersedes: Nothing Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069